Cascade power system

• US 7,469,542 B2
• Filed: 04/05/2005
• Issued: 12/30/2008
• Est. Priority Date: 11/08/2004
• Status: Active Grant

• Current Assignee: Kalina Power Limited
• Original Assignee: Kalex, LLC
• Inventors: Kalina, Alexander I.
• Primary Examiner(s): Nguyen; Hoang M
• Application Number:
  US11/099,211
• Publication Number:
  US 20060096290A1
• Time in Patent Office: 1,365 Days
• Field of Search: 606/49, 606/51, 606/71
• US Class Current: 60/649
• CPC Class Codes: F01K 25/065 with an absorption fluid remaining at least partly in the liquid state, e.g. water for ammonia F01K5/00 takes precedence

Abstract

A cascade power system and a method are disclosed for using a high temperature flue gas stream to directly or indirectly vaporize a lean and rich stream derived from an incoming, multi-component, working fluid stream, extract energy from these streams, condensing a spent stream and repeating the vaporization, extraction and condensation cycle.

Claims

1. A cascade power system comprising an energy extraction subsystem, a separation subsystem, a heat exchange subsystem, a heat recovery vapor generator subsystem and a condensation subsystem, where the system is designed to establish two interacting working fluid cycles, one cycle utilizes a rich multi-component working fluid stream having a higher concentration of a low boiling component and the other cycle utilizes a lean working multi-component working fluid stream having a lower concentration of the low boiling component, where each stream is derived from a fully condensed incoming multi-component stream and a mixed stream having substantially the same composition as the fully condensed incoming multi-component stream designed to increase an amount of the circulating rich working fluid stream, where the separation subsystem is designed to produce the lean and rich working fluid streams, where the heat exchange subsystem and the heat recovery vapor generator subsystem are designed to vaporize the lean working fluid stream and the rich working fluid stream from heat derived directly and/or indirectly from a cooled external flue gas stream comprising a mixture of a hot flue gas stream and a recycled flue gas stream extracted from the heat recovery vapor generator subsystem, where the energy extraction subsystem is designed to extract energy from the lean working fluid stream in a separate lean working fluid stream turbine or turbine stages and the rich working fluid stream in a separate rich working fluid stream turbine or turbine stages, and where the condensation subsystem is designed to condense a spent rich stream to form the fully condensed incoming multi-component stream.

2. The system of claim 1, wherein the energy extraction subsystem comprises a lean working fluid stream turbine, at least one rich working fluid stream turbine and at least two throttle control valves, where the lean working fluid stream turbine is adapted to extract energy from a lean stream, where the rich working fluid stream turbine is adapted to extract from a rich working fluid stream and where the first throttle control valve adjusts a pressure of a rich stream to that of a pressure of the rich working fluid stream turbine, where a second throttle control valve adjusts a pressure of the lean working fluid stream to a pressure of the lean working fluid stream turbine and optionally a third throttle control valve adjusts a pressure of an optional rich working fluid substream to a pressure of a leaner stream.

3. The system of claim 1, wherein the separation subsystem comprises a scrubber, a separator and three pumps, where the separation subsystem is adapted to form a lean stream and a make-up stream having a composition the same or substantially the same as an incoming working fluid stream.

4. The system of claim 1, wherein the heat exchange subsystem comprises at least four heat exchangers adapted to vaporize the rich stream and heat or partially vaporized the lean stream.

5. The system of claim 1, wherein the heat recovery vapor generator subsystem comprises a heat recovery vapor generator and a recirculating fan, where the heat recovery vapor generator subsystem is adapted cool a hot flue gas stream with a portion of a cool flue gas stream to form a cooled flue gas stream and to transfer heat from the cooled flue gas stream to the lean and rich working fluid streams and where the cooled flue gas stream has a higher flow rate than the hot flue gas stream and where the cooled flue gas stream has a desired temperature lower than a temperature of the hot flue gas stream.

6. The system of claim 1, wherein the condensation subsystem comprising a condenser.

7. The system of claim 1, wherein the condensation subsystem comprising:

a condensation separation subsystem comprising a separator adapted to produce a rich vapor stream and a lean liquid stream;

a condensation heat exchange subsystem comprising three heat exchangers and two throttle control valves adapted to mix a pressure adjusted first portion of the lean liquid stream with an incoming stream to form a pre-basic solution stream, to mix a pressure adjusted second portion of the lean liquid stream with the pre-basic solution stream to form a basic solution stream, to bring a first portion of a pressurized fully condensed basic solution stream into a heat exchange relationship with the pre-basic solution stream to form a partially condensed basic solution stream;

a first condensing and pressurizing subsystem comprising a first condenser and a first pump adapted to fully condense the partially condensed basic solution stream to form a fully condensed basic solution stream and to pressurize the fully condensed basic solution stream to form a pressurized fully condensed working fluid stream; and

a second condensing and pressurizing subsystem comprising a second condenser and a second pump adapted to mix a second portion of the fully condensed basic solution stream and the rich vapor stream to form an outgoing stream, to fully condense the outgoing stream and to pressurize the outgoing stream to a desired high pressure,

where the first portion of the lean liquid stream is pressure adjusted to have the same or substantially the same pressure as the incoming stream and where the second portion of the lean stream is pressure adjusted to have the same or substantially the same pressure as the pre-basic solution stream and where the streams comprise at least one lower boiling component and at least one higher boiling component and the compositions of the streams are the same or different with the composition of the incoming stream and the outgoing stream being the same.

8. The system of claim 1, wherein the composition of the incoming multi-component stream is selected from the group consisting of an ammonia-water mixture, a mixture of two or more hydrocarbons, a mixture of two or more freons, and a mixture of hydrocarbons and freons.

9. The system of claim 1, wherein the composition of the incoming multi-component stream comprises a mixture of water and ammonia.

10. The system of claim 1, wherein the hot flue gas stream comprises a combustion effluent stream formed from combustion of biomass, agricultural waste, municipal waste, coal, oil, natural gas and other fuels.

11. A cascade power system comprising:

a separation subsystem adapted to produce a lean working fluid stream and a rich working fluid stream form a fully condensed incoming multi-component fluid stream comprising a low boiling component and a high boiling component and a mixed stream having substantially the same composition as the fully condensed incoming multi-component stream designed to increase an amount of the circulating rich working fluid stream designed to increase an amount of the circulating rich working fluid stream, where the lean working fluid stream comprises a lower concentration of a low boiling component and the rich stream has a higher concentration of the low boiling component,

a heat exchange subsystem is adapted to heat and vaporize the rich working fluid stream and to heat the lean working fluid stream indirectly from heat derived from a cooled flue gas stream,

a heat recovery vapor generator subsystem is adapted to vaporize the lean and rich working fluid streams directly from heat derived from a cooled flue gas stream comprising the hot flue gas stream and a portion of a cool flue gas stream,

an energy extraction subsystem is adapted to convert a portion of the thermal energy in the rich working fluid stream and the lean working fluid stream to a usable form of energy, and

a condensation subsystem adapted to fully condensing the spent rich stream to form the fully condensed incoming working fluid stream,

where the system establishes two interacting working fluid cycles, a lean stream cycle and a rich stream cycle designed to improve the efficiency of energy conversion of thermal energy from the external flue gas stream.

12. The system of claim 11, wherein the energy extraction subsystem comprises a lean stream turbine, at least one rich stream turbine and at least two throttle control valves, where the lean stream turbine is adapted to extract energy from a lean stream, where the rich stream turbine is adapted to extract from a rich stream and where the first throttle control valve adjusts a pressure of a rich stream to that of a pressure of the rich stream turbine, where a second throttle control valve adjusts a pressure of the lean stream to a pressure of the lean stream turbine and optionally a third throttle control valve adjusts a pressure of an optional rich substream to a pressure of a leaner stream.

13. The system of claim 11, wherein the separation subsystem comprises a scrubber, a separator and three pumps, where the separation subsystem is adapted to form a lean stream and a make-up stream having a composition the same or substantially the same as an incoming working fluid stream.

14. The system of claim 11, wherein the heat exchange subsystem comprises at least four heat exchangers adapted to vaporize the rich stream and heat or partially vaporized the lean stream.

15. The system of claim 11, wherein the heat recovery vapor generator subsystem comprises a heat recovery vapor generator and a recirculating fan, where the heat recovery vapor generator subsystem is adapted cool a hot flue gas stream with a portion of a cool flue gas stream to form a cooled flue gas stream and to transfer heat from the cooled flue gas stream to the lean and rich working fluid streams and where the cooled flue gas stream has a higher flow rate than the hot flue gas stream and where the cooled flue gas stream has a desired temperature lower than a temperature of the hot flue gas stream.

16. The system of claim 11, wherein the condensation subsystem comprising a condenser.

17. The system of claim 11, wherein the condensation subsystem comprising:

a condensation separation subsystem comprising a separator adapted to produce a rich vapor stream and a lean liquid stream;

a condensation heat exchange subsystem comprising three heat exchangers and two throttle control valves adapted to mix a pressure adjusted first portion of the lean liquid stream with an incoming stream to form a pre-basic solution stream, to mix a pressure adjusted second portion of the lean liquid stream with the pre-basic solution stream to form a basic solution stream, to bring a first portion of a pressurized fully condensed basic solution stream into a heat exchange relationship with the pre-basic solution stream to form a partially condensed basic solution stream;

a first condensing and pressurizing subsystem comprising a first condenser and a first pump adapted to fully condense the partially condensed basic solution stream to form a fully condensed basic solution stream and to pressurize the fully condensed basic solution stream to form a pressurized fully condensed working fluid stream; and

a second condensing and pressurizing subsystem comprising a second condenser and a second pump adapted to mix a second portion of the fully condensed basic solution stream and the rich vapor stream to form an outgoing stream, to fully condense the outgoing stream and to pressurize the outgoing stream to a desired high pressure,

where the first portion of the lean liquid stream is pressure adjusted to have the same or substantially the same pressure as the incoming stream and where the second portion of the lean stream is pressure adjusted to have the same or substantially the same pressure as the pre-basic solution stream and where the streams comprise at least one lower boiling component and at least one higher boiling component and the compositions of the streams are the same or different with the composition of the incoming stream and the outgoing stream being the same.

18. The system of claim 11, wherein the external flue gas stream comprises a combustion effluent stream formed from combustion of biomass, agricultural waste, municipal waste, coal, oil, natural gas and other fuels.

19. The system of claim 11, wherein the composition of the incoming multi-component stream is selected from the group consisting of an ammonia-water mixture, a mixture of two or more hydrocarbons, a mixture of two or more freons, and a mixture of hydrocarbons and freons.

20. The system of claim 11, wherein the composition of the incoming multi-component stream comprises a mixture of water and ammonia.

21. A method comprising:

mixing a fully condensed incoming work fluid stream comprising a low boiling point component and a high boiling component with a pressurized cooled mixed stream to form a rich working fluid stream, where the incoming stream and the rich working fluid stream have the same or substantially the same composition;

bringing the rich working fluid stream into a heat exchange relationship with a mixed stream to form a cooled mixed stream and a heated rich working fluid stream;

bringing the heated rich working fluid stream into a heat exchange relationship with a first portion of a cooled spent lean working fluid stream to form a hotter rich working fluid stream and a cooled first portion of cooled spent lean working fluid stream;

bringing the hotter rich working fluid stream into a heat exchange relationship with a spent lean working fluid stream to form a fully vaporized rich working fluid stream;

adjusting a pressure of the fully vaporized rich working fluid stream to a pressure of a rich working fluid stream turbine;

converting a portion of thermal energy in the fully vaporized rich working fluid stream into a first amount of a usable form of energy;

bringing the lean working fluid stream into a heat exchange relationship with a cooled external flue gas stream to form a heated lean working fluid stream;

bringing the heated lean working fluid stream into a heat exchange relationship in a heat recovery vapor generator subsystem comprising a heat recovery vapor generator and a recirculating fan with a cooled flue gas stream to form a fully vaporized lean working fluid stream, where the cooled flue gas fluid stream comprises a hot flue gas stream and a portion of a cool flue gas stream taken from an intermediate point of the heat recovery vapor generator;

adjusting a pressure of the fully vaporized lean stream to a pressure adjusted to a pressure of the lean working fluid stream turbine;

converting a portion of thermal energy in the fully vaporized lean working fluid stream into a second amount of the useable from of energy;

scrubbing a second portion of the cooled lean working fluid stream and a pressure adjusted first portion of a separator lean liquid stream to form a liquid lean working fluid stream and a rich scrubber stream;

pressurizing the liquid lean working fluid stream to a desired higher pressure to form the lean working fluid stream;

mixing the rich scrubber stream and the cooled second portion of the cooled spent lean working fluid stream to form a pre-separator feed stream;

separating the pre-separator feed stream to form a separator lean liquid stream and a separator rich liquid stream;

mixing a second portion of the separator lean liquid stream with the separator rich liquid stream to form the mixed stream; and

condensing a spent rich working fluid stream to form the fully condensed incoming working fluid stream.

22. The method of claim 21, wherein the external flue gas stream comprises a combustion effluent stream formed from combustion of biomass, agricultural waste, municipal waste, coal, oil, natural gas and other fuels.

23. The method of claim 21, wherein the composition of the incoming multi-component stream is selected from the group consisting of an ammonia-water mixture, a mixture of two or more hydrocarbons, a mixture of two or more freons, and a mixture of hydrocarbons and freons.

24. The method of claim 21, wherein the composition of the incoming multi-component stream comprises a mixture of water and ammonia.

25. The method of claim 21, further comprising:

splitting the fully vaporized rich working fluid stream into two substream, one being forwarded to the rich working fluid stream turbine and the other being pressure adjusted and mixed with the heated lean working fluid stream prior to fully vaporization.

26. A method for efficient extraction of energy from a hot flue gas stream comprising the steps of:

establishing two interacting vaporization and energy extraction cycles, where one cycle utilizes a multi-component fluid stream having a higher concentration of a low boiling component of the multi-component fluid, a rich working fluid stream, and the other cycle utilizes a multi-component fluid stream having a higher concentration of a high boiling component of the multi-component fluid, a lean working fluid stream, each stream being derived from a fully condensed incoming multi-component working fluid stream and a mixed stream having substantially the same composition as the fully condensed incoming multi-component stream designed to increase an amount of the circulating rich working fluid stream designed to increase an amount of the circulating rich working fluid stream;

vaporizing the lean and rich working fluid streams utilized in the two interacting cycles from heat derived directly and/or indirectly form a hot flue gas stream, where the direct heat transfer occurs between a cooled flue gas stream comprising a hot flue gas stream and a portion of a cool flue gas stream and the lean and rich working fluid streams;

converting a portion of thermal energy associated with the lean working fluid stream and the rich working fluid stream to a usable form of energy to form a spent rich working fluid stream and a spent lean working fluid stream,

separating a portion of the spent lean working fluid stream to form the lean working fluid stream and a make-up stream, where the make-up stream has a composition the same or substantially the same as the incoming multi-component working fluid stream; and

condensing the spent rich working fluid stream to form the fully condensed incoming multi-component working fluid stream The spent rich stream is forwarded to a condensation unit, where it is fully condensed to form the incoming stream.

27. The method of claim 26, wherein the external flue gas stream comprises a combustion effluent stream formed from combustion of biomass, agricultural waste, municipal waste, coal, oil, natural gas and other fuels.

28. The method of claim 26, wherein the composition of the incoming multi-component stream is selected from the group consisting of an ammonia-water mixture, a mixture of two or more hydrocarbons, a mixture of two or more freons, and a mixture of hydrocarbons and freons.

29. The method of claim 26, wherein the composition of the incoming multi-component stream comprises a mixture of water and ammonia.